In-mold label forming surfaces for molded articles

ABSTRACT

A method of making a molded article having a curved surface, such as plates or serving trays, and the resulting molded articles. The in-mold label (IML) is a laminated film that includes a backing layer, a printed surface incorporating one or more designs thereon, a protective film layer, and one or more notches each having adjacent edges separated by a gap of predetermined distance and configured to intersect to ensure conformance of the IML to the angled or curved peripheral portion of the article. The article has front and back sides and a central portion bounded by a peripheral portion having a perimeter that is raised on the front side of the article wherein the peripheral portion transitions from the perimeter to the central portion by an angled surface, a curved surface or combinations thereof, with the article including the IML at least peripheral portion of the molded article.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 14/052,527filed Oct. 11, 2013, now U.S. Pat. No. 8,968,618, which claims thebenefit of application No. 61/847,387 filed Jul. 17, 2013. The entirecontent of each prior application is expressly incorporated herein byreference thereto.

FIELD OF TECHNOLOGY

The present invention relates to systems and methods for integrating oneor more graphic designs as a surface on a molded article. This istypically achieved by providing the designs on a label that isincorporated into the article during a molding process.

BACKGROUND

Labels that are integrated with a mold surface to achieve a desiredaesthetic effect are commonly known as “in-mold labels” (IMLs). IMLs arefrequently used in the fabrication of molded articles for aestheticenhancement thereof. Such molded articles are typically consumerproducts such as cups, containers and complementary items that can bemixed and matched to attain a plurality of aesthetic effects whileretaining the functional attributes of the molded articles.

Attempts have been made for optimal positioning of IMLs as surfaces ofmolded resins that are not readily receptive to other types ofdecorative application (e.g., paints, inks, decals and the like). Forexample, U.S. Pat. No. 5,498,307 to Stevenson is directed to a method ofin-mold labeling using an adhesive. The method includes forming apattern structure by applying indicia to a first layer made from aspecific plastic material. A clear second layer made from the specificplastic material is applied over the first layer, the first and secondlayers are bonded. The pattern structure is applied to an interiorsurface of a mold cavity, and the mold cavity is charged with thespecific plastic material. An adhesive retains the pattern structure inthe mold cavity. The pattern structure and plastic material are heated,thereby disbursing the plastic material to form a shape of a plasticpart. After the plastic part is cooled, the part is removed from themold cavity with the pattern structure as an integral part of theplastic part.

This method, along with other known methods and devices, anticipatesknown deficiencies in adhesive systems. It is understood that theplacement of a graphic in an inner mold cavity should be consistent toensure accurate application of the graphic on each molded article. Thegraphic should not come loose from the mold during the molding process,either as a result of the heating and cooling cycle or as a result ofresin abrasion during the molding process. If the graphic wrinkles orcurls during the molding process, the molded part will be aestheticallyruined and therefore unfit for commercial sale.

Despite these known methods and devices, adhesive retention of a patternstructure is still required, thereby introducing material and temporalcosts into the molding process. Even with adhesive retention, priorapproaches dismiss the importance of complete or contoured graphiccoverage on a molded article surface and integration of designs for useof the molded article by consumers and potential consumers.

In addition, prior approaches have avoided the application of IMLs toplastic plates, serving dishes, utensils and other complex curvedsurfaces intended for serving and/or handling food. Typical applicationsof the IML are made on an essentially flat surface that is eventuallysold as a food container (e.g., a yogurt container), or on outerportions of cylindrical containers that have a uniform curvatureallowing for the smooth placement of a flat label that may or may nothave cut out portions. For products contemplated for food service,however, previous label concepts required pre-folded labels havingexpensive laminate configurations that are not food-grade quality or arenot intended to come into contact with food but instead are applied tothe outside of a food container, such as a yogurt cup (see, e.g., thedisclosure and discussion athttp://www.talkgraphics.com/showthread.php?36444-Creating-labels-for-curved-surfaces).Scored labels also exist, but these are also generally used for applyinga label to the outer surface or a cup, cylindrical or polygonalcontainer.

A need therefore persists for improved approaches to graphic labels andtheir employment in the integration of graphics with molded articles,and particularly molded articles intended for use with food.

SUMMARY OF THE INVENTION

The present invention is directed to a method of making a molded articlehaving front and back sides and a central portion bounded by aperipheral portion having a perimeter that is raised on the front sideof the article wherein the peripheral portion transitions from theperimeter to the central portion by an angled surface, a curved surfaceor combinations thereof, with the article including an in mold label(IML) at least on the angled or curved peripheral portion of thearticle. The method comprises:

providing an in-mold label;

providing a mold used in a molding process during which the moldedarticle is fabricated, with the mold having a mold cavity formed byfirst and second molding surfaces with the first surface correspondingto the front side of the article and the second surface corresponding tothe back side of the article, into which cavity resin is deposited toform the article and from which the molded article is extracted;

transferring the IML to the mold so that the printed surface of the IMLis placed adjacent one of the molding surfaces of the mold cavity;

closing the mold by bringing the other of the molding surfaces intoposition to form the mold cavity;

delivering the resin to the mold cavity having the IML therein; and

recovering the molded article from the mold with the IML present atleast on the peripheral portion of the molded article.

Suitable IMLs are those that comprise:

a laminated film, comprising a backing layer, a printed surfacesupported by the backing layer, with the printed surface incorporatingone or more designs thereon, and a protective film layer upon theprinted surface; and

one or more notches spaced along the perimeter of the IML with eachnotch having adjacent edges separated by a gap of predetermined distanceand configured to intersect to ensure conformance of the IML to theangled or curved peripheral portion of the article.

Advantageously, the IML is electrostatically charged prior todisposition in the mold and the printed surface of the IML includes oneor more aesthetic designs. The IML may be placed on the mold surfacethat forms the front side of the molded article, with the backing layerof the IML contacting the peripheral portion of the front side of themolded article and the protective layer forming part of a front surfaceof the molded article, with the protective film layer being sufficientlytransparent so that the aesthetic design is visible therethrough.Alternatively, the IML may be placed on the mold surface that forms theback side of the molded article, with the backing layer of the IMLcontacting the peripheral portion of the back side of the molded articleand the protective film layer forming part of a back surface of the backside of the molded article, with the molded article and backing layerbeing sufficiently transparent so that the aesthetic design is visibletherethrough. The backing layer preferably comprises a clear layer ofpolypropylene or polystyrene, and the protective film layer comprisespolypropylene or polyester. In accordance with good molding practices,the method includes subjecting the resin to a heating and cooling cyclefor controlling resin flow and retaining the molded article shape.

The method may also include custom fitting the IML label to conform tothe molded article before transferring the IML to the mold surface byconfiguring the one or more notches of the IML to have adjacent edgesseparated by a predetermined distance and configured to intersect toensure conformance of the IML to angled curved mold surfaces during themolding process without perceptible wrinkling, wherein optionally aminimum intersection of 0.5 mm is provided. The custom fitting caninclude providing the IML and molded article with a generally polygonalgeometry with each one notch provided at each corner of the IML and eachgap configured to intersect along sharp corners wherein walls of theperipheral portion of the molded article come together. For thisembodiment, the IML and molded article each have a generally polygonalshape having 3 to 8 sides.

The molded article and IML may instead have are a round or ovalperimeter and the custom fitting further comprises providing the IML intwo or more arc segments for application to the peripheral portion ofthe molded article with each arc segment configured and dimensioned tointersect with an adjacent arc section to form a continuous surface onthe peripheral portion of the article. For this embodiment, the IML mayinclude a central segment for application to the central portion of themolded article and when so provided each arc segment of the IML includesa connection neck to the central segment to facilitate placement of theIML on the mold surface.

To facilitate injection of the resin into the mold without disturbingthe placement of the IML, the method includes providing the mold with anintegral shelf configured to retain the IML on the mold surface duringthe molding process and further configured to direct resin flow beyondan IML edge while avoiding entry of resin between the label and the moldsurface, wherein the shelf has a height about three times a thickness ofthe IML.

To facilitate manufacture of the molded articles, the method furthercomprises providing a magazine to hold multiple IMLs in place fortransfer to the mold surface. The most preferred molded articles arethose comprising a plastic plate or serving tray having a profileselected from a plurality of round, oval or polygonal profiles orcombinations thereof. When the IML includes printing on both sides ofthe backing layer, the molded article is made of clear resin so that theprinting is visible from both the front and back sides of the moldedarticle.

Another embodiment of the invention is a molded article having front andback sides and a central portion bounded by a peripheral portion havinga perimeter that is raised on the front side of the article wherein theperipheral portion transitions from the perimeter to the central portionby an angled surface, a curved surface or combinations thereof, with thearticle including an in mold label at least on the angled or curvedperipheral portion of the article. The IML comprises a laminated film,comprising a backing layer, a printed surface supported by the backinglayer, with the printed surface incorporating one or more designsthereon, and a protective film layer upon the printed surface; and oneor more notches spaced along the perimeter of the IML with each notchhaving edges that intersect to ensure conformance of the IML to theangled or curved peripheral portion of the article.

The printed surface of the IML includes one or more aesthetic designsand the backing layer of the IML contacts the peripheral portion of thefront side of the molded article with the protective layer forming partof a front surface of the molded article and with the protective filmlayer being sufficiently transparent so that the aesthetic design isvisible therethrough. As above, an alternative is that the backing layerof the IML contacts the peripheral portion of the back side of themolded article with the protective film layer forming part of a backsurface of the molded article, with the molded article and backing layerbeing sufficiently transparent so that the aesthetic design is visibletherethrough.

For optimum results, the notch edges of the IML have a minimumintersection of 0.5 mm, the molded article either has a generallypolygonal shape having 3 to 8 sides, a round or oval perimeter, or acombination thereof. The backing layer generally comprises a clear layerof polypropylene or polystyrene, the protective film layer comprisespolypropylene or polyester and the molded article is in the form of aplate or serving tray having a round, oval or polygonal plate profile ora combination thereof. The molded article and IML can have a round oroval perimeter with the IML having two or more arc segments with eacharc segment intersecting with an adjacent arc section to form acontinuous surface on the peripheral portion of the plate or servingtray and, if desired, the IML can include a central segment applied tothe central portion of the plate or serving tray and each arc segment ofthe IML includes a connection neck to the central segment, wherein eachconnection neck is clear or has a color that matches that of the plateor serving tray. As noted herein, when the IML includes printing on bothsides of the backing layer and the molded article is made of clear resinso that the printing is visible from both the front and back sides ofthe molded article.

Additional aspects of the presently disclosed invention will be madeapparent from the appended drawings and the following detaileddescription.

BRIEF DESCRIPTION OF THE DRAWINGS

The nature and various advantages of the present invention will becomemore apparent upon consideration of the following detailed description,taken in conjunction with the accompanying drawings, in which likereference characters refer to like parts throughout, and in which:

FIG. 1 shows a top view of an exemplary in-mold label (IML) having agenerally rectangular geometry.

FIG. 2A shows a top perspective view of an exemplary molded articlehaving a surface formed by the IML of FIG. 1.

FIG. 2B shows a bottom perspective view of the exemplary molded articleof FIG. 2A.

FIG. 3 shows another exemplary molded article having a surface formed byanother exemplary IML.

FIG. 3A shows design considerations for a conventional dinner plate.

FIG. 3B shows the final IML half for the dinner plate of FIG. 3A.

FIGS. 4, 4A, 5, 6, 7 and 8 show steps of an exemplary molding processfor fabricating molded articles having an IML forming at least onesurface thereof.

FIG. 9 is a partial cross-sectional view of a plastic plate fabricatedaccording to the process of FIGS. 4 to 8.

FIG. 9A is an illustration of part of the mold to show how the label isretained therein without movement when encountering resin flow.

FIG. 10 shows a sectional view of the IML showing its layers.

FIG. 11 shows a label design that covers the peripheral portion of around dinner plate as well as part of the central portion of the plate.

DETAILED DESCRIPTION OF THE INVENTION

The invention utilizes an in-mold label (IML) for forming a surface of amolded article. The label includes a laminated film having a backinglayer and a printed surface supported thereby. The printed surfaceincorporates one or more designs thereon. One or more notches may beprovided along the perimeter of the IML in spaced relation, with eachnotch having adjacent edges separated by a gap of predetermineddistance. The adjacent edges are configured to intersect to ensureconformance of the IML to curved mold surfaces during the moldingprocess. The IML is configured to avoid wrinkling upon injection of aresin in the mold cavity disposed during a molding process from whichthe molded article is fabricated.

In some embodiments, the IML may also include a protective film layerupon the printed surface. The notch edges may be configured to exhibit aminimal intersection of 0.5 mm when applied to a curved mold surface. Inembodiments where the IML has a generally rectangular geometrycommensurate with a geometry of the molded article to which the IML isapplied, the notches include a notch provided at each correspondingcorner of the IML. In such embodiments, each gap is configured tointersect along sharp corners where walls of the molded article cometogether. In other embodiments, the entire edges of the notches overlapor underlap to form what is perceived to be a seamless design.

The IML may be provided as a single member or it may be provided in twoor more sections to form one or more surfaces of a molded article. Thesections may include one of (a) at least two arc segments of a circlewhich are applied to the peripheral portion of a round molded article,or (b) a circular section applied to the center of a round moldedarticle and a further section applied to a different area of the moldedarticle. The IML preferably includes an outer periphery configured tosit just inside a perimeter of the molded article surface.

The IML can include printing on both sides if desired. Alternatively,the IML may include on the printed surface a functional ink thatprovides an indicator of temperature.

Also provided is an exemplary method of making a molded article thatincludes providing an IML as described herein. A mold is provided thatis used in a molding process during which the molded article isfabricated. The mold has a mold cavity into which resin is deposited andfrom which the molded article is extracted. The IML is transferred tothe mold so that the printed surface of the IML is placed adjacent awall of the mold cavity. Resin is delivered to the mold cavity havingthe IML therein, and the molded article is recovered therefrom.

In some embodiments, the IML is electrostatically charged prior todisposition in the mold. Alternatively, the mold is designed to providevacuum retention of the IML in the desired position in the mold.Optionally, the resin may be subjected to a heating and cooling cyclefor controlling resin flow and retaining the molded article shape withthe IML forming a surface of the molded article. The printed surface ofthe IML may be printed upon prior to placement of a layer of protectivefilm thereon. During the printing, one or more aesthetic designsselected from a plurality of aesthetic designs are incorporated on theprinted surface. In some embodiments, the printed surface forms a topsurface of the molded article. In some embodiments, the resin contactsthe printed surface such that the printed surface is visible through theresin upon curing thereof. In other embodiments, the IML may have onedesign on one side and a different design on the opposite side. Thenclear resin is molded around the label to form the article, the articlecan have one appearance on the front and a different appearance on theback.

The resin may be a thermoplastic resin and is generally introduced intothe mold at a point corresponding to a central area of the article. Amagazine may be provided during the molding process for holding multipleIMLs in place for transfer to the mold cavity.

The IML label may be custom fitted before transferring the IML to themold by providing one or more notches spaced along the perimeter of theIML. Each notch has adjacent edges separated by a predetermined distanceand configured to intersect to ensure conformance of the IML to curvedmold surfaces during the molding process. Optionally a minimumintersection of 0.5 mm is provided. The custom fitting may includeproviding the IML with a generally rectangular geometry commensuratewith a geometry of the molded article to which the IML is applied witheach notch provided at a corresponding corner of the IML and each gapconfigured to intersect along sharp corners where walls of the moldedarticle come together. Alternatively, the custom fitting may includeproviding the IML in two or more sections for application to the moldedarticle surface. With an appropriate overlapping or underlapping of theIML sections, a seamless appearance of the design can be achieved.

The mold may be provided with an integral shelf configured to retain theIML on the molded article surface during the molding process. Theintegral shelf may be further configured to direct resin flow beyond anIML edge while avoiding entry of resin between the label and the mold.The shelf may have a height about three times a thickness of the IML.Also, the IML may be electrostatically charged or held in place byvacuum to assist in providing the IML at the proper position for moldinginto the article.

During a molding process, the IML may be transferred to the mold so thatthe printed surface and protective layer face are placed adjacent a wallof the mold cavity to form a top surface of the molded article. In somemolding processes, the IML is transferred to the mold so that theprinted surface faces away from a wall of the mold cavity to form asurface of a back side of the molded article. The molded article may bea plastic plate having a plate profile selected form a plurality ofplate profiles.

Also provided is a mold having a mold cavity for the fabrication ofmolded articles thereby. The mold includes an integral shelf provided inthe mold cavity and configured to retain an IML in place relative to anarticle being molded. The mold cavity provides each molded article witha curvature to which the IML conforms. Resin is deposited into the moldcavity during a molding process with the IML conforming to the curvaturewithout wrinkling during the molding process.

A plurality of molded articles is also provided that are fabricated by amold as described herein, with each molded article having one or moredecorative patterns from one or more IMLs.

A molded article is additionally provided having one or more IMLs or IMLsections as described herein. The IML is provided as a surface withintersecting notches to form a continuous pattern supported by theplastic substrate. The molded article may be a plastic plate having aplate profile selected from a plurality of plate profiles includinground, polygonal or combinations thereof. The IML is may be provided asa top surface with an exterior protective film layer disposed thereon,with the protective film layer, which is preferably and convenientlyselected from polypropylene and polyester but which may be othermaterials. Alternatively, the plate may be fabricated from athermoplastic resin that is transparent upon cure and the IML isprovided as a surface of a back side of the plate such that thecontinuous pattern is provided on the surface of the IML that contactsthe plate and that is visible through the plate. In a preferredarrangement, both the label and article are made of the same material,e.g., polypropylene, to facilitate recycling.

Another embodiment of the invention relates to a method of providing amolded article with an in mold label (IML) that conforms to one or morelocations on the surface of the article without surrounding the article.This method comprises configuring a molded article to have top or bottomsurfaces with a certain curvature or shape; and designing the IML withone or more special features. These features comprise one or more of:

(a) one or a plurality of symmetrical notches that allow the IML toconform to a curved surface with edges of the notches intersecting;

(b) one of more sections having edges that intersect to conform to acurved surface;

(c) a predetermined arrangement to conform to a location on the articlesuch that, when placed in a mold cavity, injected resin contacts a backside of the IML to force it against the mold cavity and retain itsposition thereon during molding of the article; or

(d) an edge or edges that conform to an integral shelf provided in amold cavity so that injected resin does not flow between the IML and themold cavity or cause movement to the IML from a desired position in themold.

The IML is typically applied to the surface location(s) withoutcrinkling or buckling when the article is molded with the IML. Furtherfeatures of the method include providing a mold having a mold cavitythat receives the IML therein and injecting resin into the mold to formthe article.

Now referring to the figures, wherein like numbers represent likeelements, FIG. 1 shows an exemplary in-mold label (IML) 10 for forming asurface of a molded article. As used herein, “IML” and “label” may beused interchangeably to refer to any layer or film having a graphicintegral therewith or included thereon and which is incorporated as asurface on a molded article to achieve a variety of aesthetic choicestherefor.

The molded article may preferably be a consumer product such as aplastic plate 12 (shown and described further herein with respect toFIGS. 2A and 2B), although such molded article may be any productamenable to incorporation of one or more IMLs thereon. Plate 12 (or anyother molded article) may be fabricated from a range of suitablematerials, including but not limited to polystyrene (PS and includingHIPS), polypropylene (PP), styrene acrylonitrile (SAN), and commensuratematerials. The selected materials may be disposable, reusable and/orrecyclable. Other articles such as serving trays or bowl of othershallow containers can be provided with IMLs in accordance with theinvention.

Although IML 10 is shown as a rectangular member, it is understood thatIML may assume any geometry amenable with the practice of the presentlydisclosed invention. For example, an alternative circular IML 16 isshown and described with respect to FIGS. 4A and 5 as another exemplarylabel geometry for placement with respect to a round plate 18 (shown inFIG. 3). The geometry of the IML is not limited to these two geometriesand may be customized to form a surface commensurate with a geometry ofthe molded article to which the label is applied. For example, the platemay have a polygonal shape with rounded corners.

Referring further to FIGS. 1 and 2A, IML 10 is depicted as a generallyrectangular label having an outer periphery 10 a defined by adjacentsides 10 b. IML 10 may be a laminated film having a backing layer (notshown) for contact with a top surface 12 a of plate 12. A printedsurface 10 c supported by the backing layer incorporates one or moredesigns such as the graphic shown in FIGS. 1 and 2 a. The graphic may beselected from a plurality of aesthetic varieties and is not limited tothe graphic design shown herein.

Top surface 12 a of plate 12 is delineated by a generally rectangularperimeter 12 b. A service area 12 c is provided on top surface 12 a(e.g., to place food or other items thereon) and bounded by consecutivewalls 12 d such that a curved mold surface 12 h serves as an interfacebetween the service area and perimeter 12 b. When IML 10 forms a portionof top surface 12 a during a molding process, the graphic coverssubstantially all of service area 12 c and walls 12 d. Outer periphery10 a of IML 10 is configured to sit just inside perimeter 12 b as shownin FIG. 2A. Regardless of the geometry of the IML, the IML is providedwith an outer periphery that is configured to sit just inside theperimeter of the molded article surface and is sufficiently sized to fitthe angled or curved peripheral portions of the article.

As further shown in FIG. 2B, a bottom surface 12 e of plate 12 isfabricated from a thermoplastic resin. In the final molded article, agate mark or ejector pin mark 12 f may be visible that account fordimensional differences of the mating mold surfaces contacting theinjected polymer. Dimensional differences may be attributed tonon-uniform, pressure-induced deformation during injection, machinetolerances and non-uniform thermal expansion and contraction of moldcomponents that experience rapid cycling during the injection, packing,cooling, and ejection phases of an injection molding process.

One or more notches 10 d are provided spaced along the perimeter of theIML with each notch having adjacent edges that are separated by a gap ofpredetermined distance D and configured to intersect one another whenIML 10 forms a surface of plate 12 during a molding process (as furtherdescribed hereinbelow). As used herein, “notches” refer to incisions,slits, cuts and scores that are intentionally created and positioned inan IML to ensure predictable and repeatable integration of a decorativesurface upon a molded surface of complex curvature. Generally thesenotches have a V shape with the angle of the V being a small acute anglewhich is calculated so that the IML conforms to the angled or curvedsurfaces of the molded article. As used herein, the term “intersect”means that the label edges are in adjacent relation such that there is avisually perceived continuity of the design or information on thearticle. Preferably, the visually perceived continuity of the design orinformation appears to be seamless. Thus, “intersect” includesarrangements that include overlap or underlap of the edges of the labelportions as well as contact along or meeting of the edges. In someembodiments, the edges of the notches can simply be placed sufficientlyclose and adjacent each other without contact but without distorting thevisible pattern of the design. Preferred adjacent distances of 0.005 to0.05 mm are useful depending upon the specific design while overlapprovides optimum results for others. When seamless complex designs aredesired, the IMLs or IML sections will typically overlap or underlap byat most a few millimeters in order to assure that the pattern or thedesign will repeat in a continuous or seamless fashion. The overlap orunderlap will typically be in the range of 0.5 to 1 mm.

The use of a slight overlap in the present invention is a significantdeparture from prior IMLs as it was understood by skilled artisans thatunintentional or even intentional overlapping of label edges would leadto buckling, wrinkling or crinkling of the IML in the final article. Thepresent invention achieves substantial improvements in continuity of thedesign or pattern by utilizing this heretofore undesired feature ofoverlapping or underlapping, at least in part because of the preciseengineering positioning of the IML segments and the controlled geometryof the cut out notches or portions as described herein.

In embodiments where IML 10 exhibits a rectangular geometry, each notch10 d is provided at a corresponding corner of the IML and each gap isconfigured to intersect along sharp corners 12 g where walls 12 d of theplate come together. In some embodiments, the notch edges are configuredto exhibit a minimal intersection of 0.5 mm when applied to a curvedmold surface. In this manner, IML 10 is configured to avoid wrinklingupon injection of a resin in a mold cavity disposed during a moldingprocess from which plate 12 is fabricated, while the intersection of theedges provides a continuous pattern with a minimum of space betweenthem, with no space at all being visible especially when an overlap orunderlap is included. An intersection of more than a few millimeters isgenerally not necessary.

In most embodiments, IML 10 may further include a protective film layer(see FIG. 10) upon printed surface 10 c. In such embodiments, thelaminated film comprises polystyrene polypropylene, or other suchmaterial compatible with the base layer of the label and/or substratelayer and the protective film layer is selected from polypropylene andpolyester. Other materials can be used if desired but polypropylene ispreferred due to its ready availability, compatibility withpolypropylene molding resin and ease of recycling. The laminated film istypically clear or transparent although it may be provided with a colorthat does not mask or that complements the design or other printedindicia of the IML.

Although IML 10 may be provided as a single integral label as shown inFIGS. 1 and 2A, the IML may be provided in two or more sections orsegments for application to form one or more surfaces of a moldedarticle. For example, IML 10 may include at least two sections toachieve a variety of aesthetic features (e.g., a selected designprovided along one wall 12 d of plate 12 and a second selected designprovided along an opposite wall 12 d of the plate). Preferably, thedesign is continuous around the periphery of the plate.

As shown in FIG. 3, a plate 18 is generally circular and has an IML 16forming a surface 16 a along a plate wall 18 a and another surface 16 balong plate service area 18 b. IML 16 provided along surface 16 a may beprovided in two or more sections with if necessary notches providedbetween adjacent sections such that adjacent edges of the notchesintersect during a molding process. In such embodiments, IML 16 has atleast a third portion that forms surfaces 16 b. Surfaces 16 a and 16 bmay have matching graphics or may include different graphics to achievea desired aesthetic effect.

In conforming a particular IML to a curved surface of the article,mathematical modeling may be developed for the relationships betweenslope, radius of curvature, and the placement of slits or more complexopenings to prevent wrinkling of the IML during placement and molding.These may be complex but can be computer assisted to reduce the trialand error time for conformance of the IML to the particular curvedsurface.

Now referring to FIGS. 4-8, an exemplary method of making andconfiguring a molded article is illustrated. As used herein, a “plasticpart” or “shaped part” refers an article fabricated according to amolding process as described herein prior to removal of the article froma mold cavity. As used herein, a “molded article” refers to an articlefabricated according to a molding process as described herein afterremoval of the article from the mold cavity.

Referring to FIGS. 4 and 4A, a mold 30 is provided for producing one ormore molded articles such as one or more plastic plates 18 (as shown inFIGS. 3, 7 and 8). Mold 30 includes a mold base 32 having one or morecavities 32 a for shaping a plastic part during a molding process. Moldbase 32 cooperates with a mold core 34 having one or more profiles 34 athat cooperate with corresponding cavities 32 a in mold base 32 during amolding process. A thermoplastic material 36 is fed through mold base 32(e.g., via a sprue or nozzle 38) through channels 40 that deliver moltenmaterial or resin to each cavity 32 a. Mold base 32 may include anejection system (not shown) as known in the art to eject a plastic partfrom open mold cavities 32 a when a clamping unit separates the moldhalves.

One or more robotic assemblies may be employed for the transport of IMLsand molded articles. An exemplary robotic assembly 42 is shown in FIGS.4A, 5, 7 and 8 that includes multiple grippers 42 a for handling IMLsand plastic parts. Each gripper 42 a may include a plurality of fingers42 a′ that transport IMLs into mold 30 and finished molded articles outof mold 30. One or more of fingers 42 a′ may include an attachmentmeans, such as a suction assembly (not shown), at a gripping extentthereof.

The IMLs can be provided in a magazine for collection by the roboticassembly for delivery into the mold. The IMLs can be pre-cut and stackedin the magazine to facilitate pickup by the gripper. Alternatively, thelabels can be provided in an un-slit configuration, and a slittingdevice can provide the notches in the label either when the otherwiseunslit IMLs are being placed into the magazine, or even after the IMLshave been loaded into the magazine. Alternatively, the un-slit IMLs canbe slit after removal from a first magazine and then the slit or notchedIMLs can be retained in a second magazine that cooperates with thegrippers for introducing the IMLs into the mold. A skilled artisan candevise many different systems for slitting or notching the IMLsconsistent with the disclosure herein. For example, die cutting is asimple and straightforward way of providing the notches in the IMLsprior to their introduction into the mold. If desired, the IMLs can bedie cut just prior to their introduction in the mold.

Robotic assembly 42 is entrusted with several tasks, including but notlimited to (a) retrieving one or more IMLs 16 (e.g., from a magazinethat holds multiple IMLs in place for transfer to mold 30); (b) passingeach IML within proximity of an electrostatic charger 44 (see FIGS. 4, 7and 8) in those embodiments where the IMLs are electrostatically chargedprior to entry in mold 30; (c) accurately positioning each IML relativeto a corresponding profile 34 a and cavity 32 a prior to a moldingprocess; (d) retrieving a plastic part from each mold cavity 32 a uponcompletion of a molding process; and (e) placing the final moldedarticles (e.g., in an article transfer station) for further processing.Robotic assembly 42 may be selected from one or more commerciallyavailable robot picker configurations, including but not limited toindependently actuatable automatic arms. A programmable controller maybe programmed to move robotic assembly 42 relative to mold 30 and topick up and release IMLs 16 and plastic plates 18 by controllinggrippers 42 a.

Although electrostatic charging of the IML is preferred, it is alsopossible to design the mold with appropriate ports to apply a vacuum tohold the label in place. In this alternative embodiment, the mold wouldbe made using aluminum or ceramic tooling which is much more amenable tovacuum retention. In some situations, depending upon IML and articleshape, vacuum retention can be used in steel molds as well.

The IMLs can be a flat label that is customized with one or more notchesor slits in consideration of the molded article geometry. The flatlabels with the notches can be placed into the magazine for gripping bythe robot for placement into the mold. Such custom-fit labels can bedesigned to conform to almost any geometry although the deepercurvatures require more engineering and are not always necessary toachieve satisfactory results.

In other embodiments, the IML may have one design on one side and adifferent design on the opposite side. After clear resin is moldedaround the label to form the article, the article can have oneappearance on the front and a different appearance on the back. Suchtwo-sided or double-sided printing can also be used to provide a“decorated” side to the IML and an “informational or instructional” sideto the IML. The informational or instructional side may include useinstructions, recipes, details for cleaning or reusing the article, orhow to recycle or dispose of the article. It also can include origin ofmanufacture, type of material, design pattern name or other identifyingindicia. Again, after clear or transparent colored resin is moldedaround the IML to form the article, the article can have a designappearance on the front and instructional information for the appearanceof the back.

The IML may also be specially designed for a particular purpose. IMLsthat incorporate thermo-chromatic inks, 3-D effects, and the like can beused for special effects or measurements. For example, an IML thatincludes thermo-chromatic inks allow the article to be used as athermometer or other heat indicator. As the article is disposable, thiscould be discarded after use rather than a conventional thermometerwhich would have to be cleaned or sterilized before reuse.

The following is an example of how to design a particular IML for aconventional round dinner plate having an angled peripheral portion, Ithas been found that optimum results are obtained when two peripheralportion arc segments are used, each covering about half of theperipheral portion of the plate with a small overlap to assurecontinuity of the pattern or design. These “half labels” are targeted tomaximize IML yield. The plates generally have a flat angled peripheralportion. This peripheral portion can be considered as a very wide conewith the applicable mathematical equations for cones being utilized tocalculate the dimensions of the IML. A computer can be used tofacilitate these calculations.

First, a relationship between cone surface area and unfolded cone net isestablished by inputting plate dimensions into cone equations, andapplying output calculations to the IML design. A relationship betweenthe cut out angle φ and the cone angle θ can be established as follows(calculations appear in Appendix A of provisional application61/847,387):Φ=2π(1−sin θ)The plate rim angle θ is either measured or selected as desired. Then,the notch cut out angle is calculated in radians from the equation.

To measure the plate rim angle, a plane P is projected tangent to therim and peripheral portion 16 a of the plate 18 as shown in FIG. 3A. Theprojection plane is also angularly offset from a vertical plane at therim angle. On this plane, circles are drawn to “unfold” the wide coneformed by the peripheral portion of the plate into a flat net withoutany cut out portion. The cut out is calculated by dividing the net by 2to obtain the size of the 2 label halves and then dividing by 2 againbecause each half of the net has two ends. This amount is thensubtracted from each end of the label.

Finally, the desired overlap is added to each side of the label: this istypically between 0.2 and 1 mm. For this example, 0.25 mm is added toeach end to achieve a nominal overlap of 0.5 mm on each end of thelabel. The total overlap or underlap should be less than 2 to 3 mm aslarger amounts could lead to wrinkling of the label during moldingoperations.

The final label halves, shown as 20 and 21 in FIG. 3B, conform toessentially the entire peripheral portion of the article, and areapplied in the mold so that the ends of two halves 20 a and 21 a and 20b and 21 b overlap to conform the final conical shape of the plate. Thedesign or ornamentation to be provided on the label can be configured torepresent a continuous pattern. If the pattern is a simple stripe orbar, this is easily achieved while additional effort may be needed sothat the ends of the two label halves match a repeating pattern of,e.g., flowers or geometric shapes.

Prior to injection of material 36 into mold base 32, the two mold halves32, 34 are securely closed by a clamping unit as is known in the art.Mold base 32 remains fixed in communication with nozzle 38 while moldcore 34 exhibits reciprocating movement relative to the mold base. Theclamping unit pushes the mold halves 32, 34 together and exerts a forcesufficient to ensure closure of mold 30 during injection of material 36into mold cavities 32 a.

As shown in FIGS. 4 and 4A, thermoplastic material 36 is provided forintroduction into channels 40 of mold base 32. A ram 46 exerts pressureupon material 36 such that material 36 melts and enters mold base 32 vianozzle 38. Channels 40 carry the molten material from nozzle to cavities32 a. Upon termination of each channel, molten material enters eachcavity 32 a through a gate 48 that directs material flow. The moltenmaterial that cures within channels 40 is attached to the shaped partand must be separated after the part has been ejected from the mold(i.e., resulting in the formation of a gate mark such as gate mark 12 fshown with respect to plate 12 of FIG. 2B). Hot and/or cool channelsystems may be employed to direct the melting and cooling of the moltenmaterial as needed for specific molded articles. The molten material (orresin) may be subjected to at least one heating and cooling cycle forcontrolling resin flow and retaining the shaped part with the IMLultimately forming a surface of the molded article.

The resin may be clear or colored as desired. It may also be transparentor translucent as desired. Any color can be used with white, black, goldor silver being preferred. As noted herein, clear or transparent coloredresin is used when the IML is on the underside of the molded article sothat the design or information can be viewed through the article, Thecolor of the article can also be designed to cooperate with or form partof the pattern: e.g., a white plate can provide the background for thedesign such that space between the edges of the cut notches does notdetract from the pattern design. Other designs can allow the color ofthe plate to be viewed through the label, either by using a label havinga clear substrate or by providing holes or “windows” though an opaquelabel. It is understood that the IMLs may include ornamentation ordecoration on all or only part of the segments as desired.

In FIGS. 4 and 4A, robotic assembly 42 transports IMLs 16 in proximityof electrostatic charger 44 to ensure retention of each IML relative toa corresponding profile 34 a as shown in FIG. 5. Referring to FIGS. 5and 6, material 36 is melted by heat and pressure and injected intocavities 32 a rapidly to ensure retention of the material in the desiredshape. Molten material 36 begins to cool as soon as it contacts interiorsurfaces of cavities 32 a and exterior surfaces of profiles 34 a.

Referring to FIG. 7, the material cures in the shape of the plastic partand, upon expiration of the required cooling time, the cooled plasticpart may be ejected from mold 30 to reveal the final molded article(i.e., plastic plate 18). Because during cooling the plastic partshrinks and adheres to the mold, a mold release agent may be sprayedonto the surfaces of cavities 32 a prior to injection of material 36.Referring to FIG. 8, robotic assembly 42 may transport plates 18 frommold cavity 32 a to a processing region and select new IMLs 16 forplacement on profiles 34 a in a subsequent molding process.

Material 36 may be polypropylene, polystyrene or any other thermoplasticmaterial that, upon curing, exhibits high impact strength, rigidity,toughness and dimensional stability at low cost. Preferably,polypropylene is used as it results in a molded article that can berecycled. Colorants may be added during the molding process to controlthe color of the molded article. If the molded article is clear, the IMLmay instead be placed along at least a portion of the bottom surface ofthe perimeter portion of the molded article. In such embodiments, theresin contacts the printed surface of the IML and is therefore visiblethrough the resin upon the curing thereof. The resin of the moldedarticle also prevents food contact with the inks that provide thedecoration, ornamentation or information on the IML.

FIG. 9 illustrates the cross section of a molded plate 50 according tothe invention. The plate 50 has an angled peripheral portion 51 whichbegins at a line 52 between where the plate is provided with a deepercurvature and extends outward to a flange 53 at the perimeter of theplate. The IML can be provided on the top 55 of the peripheral portionwhere it extends from line 52 to near the flange 53. The exact width ofthe IML can vary depending upon the design that is to be provided to thearticle, and it can span the entire peripheral portion or only part ofit. Where the IML is providing a line or solid band to the article, theentire peripheral portion is not covered, whereas when the IML isproviding, e.g., a floral or artistic pattern, the IML covers more toalmost all of the width of the peripheral portion. The precise size ofthe IML thus depends upon the design, but when it is provided on the top55 of the peripheral portion, the ink printing or other applieddecoration or pattern is preferably protected by a film so that it doesnot contact food or other edible items that are placed on the plate. Ofcourse, if food grade inks are used or if the article is not used forfood service, e.g., when used as a base plate for plants or as walldecorations, or as a serving tray to carry items other than exposedfoodstuffs, then the protective layer is not required. Advantageously,the inclusion of a protective layer in these non-essential applicationscan serve to preserve the inked design or decoration and prevent themfrom damage due to abrasion or wear due to contact with other articles.

FIG. 9A illustrates how the IML is retained in place during resinintroduction for the molding process. Mold cavity 32 a is provided withan integral shelf or step 62 configured to retain the IML 55 in placewhile resin 64 is injected into the mold during the molding process.Shelf 62 is further configured to direct resin flow beyond where the IML55 sits on the shelf 62 to thus avoid having the rapidly flowing resineither move or displace the IML or enter between the IML and mold topossible obscure or interfere with the development of the desiredornamentation or pattern.

In FIG. 9A, IML 55 is statically charged and held to the B side of tool68 before resin 64 is injected between the B side of the tool and the Aside of the tool 66. The retaining shelf or step 62 helps properly alignthe IML in the mold and protects it from resin flow during injection. Asresin 64 is injected into the mold, the flow front 65 is directed overthe edge 56 of the IML 55 after contacting the retaining step 62.

Each mold cavity 32 a provides each molded article with a curvature towhich the IML conforms. Thus, as resin is deposited into the mold cavityduring the molding process, the IML conforms to the curvature withoutwrinkling Shelf 62 has a height that is approximately three times thethickness of the IML. Typically the label has a thickness of about 0.01to 0.05 mm and preferably 0.03 mm. Thus, the shelf has a height ofbetween about 0.03 to 0.15 mm and preferably about 0.9 mm.

In some embodiments, the IML has a thickness that is about the same asthe height of the shelf but in these embodiments, the resin in injectedso that it directly contacts the IML, thus holding it more strongly inposition and preventing undesired movement of the IML.

In other embodiments, the IML can be provided in the center of thearticle, arranged so that the introduction of resin into the mold isdesigned to be directed at a central area or center of the IML on eitherthe front or back side to assist in holding the IML in position as resinfills the mold. For the square plate embodiment shown herein, the gatemark (12 f in FIG. 2B) would be the point where the resin would beintroduced into the mold. On a round plate, a round or polygonal labelmay be centered in the middle of the plate. Of course, a round orpolygonal label could be used for the square plate instead of a squarelabel. As the central areas of these plates are generally flat, nospecial consideration is needed for the IML and a flat, unnotched IMLcan be used in these areas.

Referring to FIG. 10, a sectional view of the label is provided to showthe arrangement of the laminate layers of the IML on the molded plasticsubstrate. The IML 70 has a three-layer construction. The base orsubstrate 72 of the label is made of a plastic material that typicallyis capable of bonding to the resin that is used to form the moldedarticle. One surface of the substrate 72 includes a printed layer 74,typically ink, which includes the design, pattern, written informationor other indicia that forms the decoration or information of the IML. Ifdesired, the printed layer could be a separately printed sheet thatadheres to the substrate but it is easier in most cases to simply printupon the backing layer. Finally, for the embodiments that requireisolation of the printed surface from contact with food, a protectivelayer 76 is provided. As noted herein, even when the article is not tobe used for contact with food, the protective layer is desirable andpreferred to prevent deterioration or wear of the design or informationon the label. The present labels that include the protective layer aredistinguishable from conventional IMLs such as those used for yoghurtcontainers where the printed designs or information are outside of thecontainer and are not intended to be in contact with food.

Returning to the dinner plate embodiment shown in FIG. 3, FIG. 11illustrates a preferred IML for molding into round dinner plates. TheIML has a two arc segments 22, 24, each configured with ends 22 a, 22 b,24 a, 24 b, respectively. End 22 a is spaced from end 224 a and end 22 bis spaced from end 24 b as disclosed herein so that these ends intersectafter being molded into the plate due to conformance of the IML to theangled peripheral portion of the plate to form a continuous surfacethereon. The IML 25 also includes a central segment 26 that is designedto be applied to the central portion of the plate. The central segmentcan be sized as desired to provide almost full coverage of the plate asshown or in a smaller size such as is shown in FIG. 3. Each of the twoarc segments 22, 24 includes a connection neck 22 c, 24 c to the centralsegment 26. While the connection necks can be provided withornamentation or aesthetic designs, they also can be made of clear IMLmaterial or with a color that matches that of the plate (e.g., white fora white plate) so that they are not visible in the final design. Thus,IML 25 can be designed to provide the ornamentation shown in FIG. 3 withthe connection necks not being evident with the molded article havingthe appearance of that shown in FIG. 3. Alternatively, multipleconnection necks can be provided if desired when additional decorationor ornamentation is desired on the plate (e.g., a “wheel spoke” design).The provision of the IML with the arc segments and central segmentjoined together facilitates placement of the IML in the mold and themaintenance of the segments in the proper position to receive the resinduring molding. The central segment 26 is also desirable as the resininjected into the mold can be directed at the center portion of thecentral segment 26 to assist in not moving the label during the moldingprocess.

While the IML 25 of FIG. 11 may also be configured to fit oval orpolygonal or combinations these (i.e., polygonal shapes with rounded orarcuate corners joining the sides. As noted preferred polygonal plateshave 3 to 8 sides although other numbers of sides can be used ifdesired. When multiple arc or polygonal segments are used, each separatesegment can be connected to the central segment by a neck connector.Also, instead of use of the label on plates, the molded article can alsobe a serving tray or shallow bowl.

The methods and devices taught herein are amenable for the creation ofplastic plates having profiles selected from a plurality of plateprofiles. With the disclosed method, IMLs are accurately positioned inmold cavities without allowing any air to become trapped between thelabels and the mold cavity surfaces. The IMLs desirably exhibit growthand shrinkage along the mold cavity surface as the mold temperaturechanges. If the IML does not have same coefficient of expansion withheat as the mold, it elongates more as the temperature rises and shrinksmore as the temperature falls. Failure of the IML to grow and shrinkcommensurate with temperature fluctuations will cause the IML to buckleand wrinkle, resulting in defective graphics.

The methods and devices disclosed herein also contemplate production ofsingle-use disposable molded articles. It is understood, however, thatmolded articles as taught herein my be suitable for re-use and/orrecycling by consumers. Advantageously, the preferred use of the moldedarticles of the invention is as a multi-use disposable plate or similararticle. This article would have the same weight and cost as currentdisposable plates, but would be able to withstand a number of washingsfor reuse. In addition, reuse of the article benefits the environment ascompared use of a traditional single-use disposable article.Furthermore, when the article and IML are made of polypropylene, theheat tolerance of that resin is higher, and thus better suited forwashing in hot water, and when the useful life of the plate is complete,it may be recycled in the same manner as other plastics.

As used herein, the term “process” or “method” may include one or moresteps. Any sequence of steps is exemplary and is not intended to limitmethods described herein to any particular sequence, nor is it intendedto preclude adding steps, omitting steps, repeating steps, or performingsteps simultaneously.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue as well as equivalent units of that value. For example, adimension disclosed as “40 mm” is intended to mean “about 40 mm” as wellas “1.58 inches”. The disclosure of such dimensions and values, however,shall not preclude use of any of disclosed devices having dimensions andvalues outside of the prescribed ranges. The term “about” is used tomean that the exact number is not critical and that a certain tolerance,such as ±10-15% is acceptable.

While the invention has been described in a preferred form, it will beunderstood that changes, additions, and modifications may be made to therespective articles forming the invention. Accordingly, no limitationshould be imposed on the scope of this invention, except as set forth inthe accompanying claims.

What is claimed is:
 1. A method of making a molded article having frontand back sides and a central portion bounded by a peripheral portionhaving a perimeter and including an outer boundary located near theperimeter and an inner boundary located near the central portion,wherein the peripheral portion on the front side of the article includesa transition from the inner boundary to the central portion of thearticle which is a shallow-angled or sloped surface, a curved surface orcombinations thereof, and with the article including an in mold label(IML) at least on the angled, sloped and/or curved peripheral portion ofthe article, which method comprises: providing an in-mold labelcomprising at least two separate arc segments of a laminated film thatincludes a backing layer, a printed surface supported by the backinglayer, with the printed surface incorporating one or more designsthereon, and a protective film layer upon the printed surface, with thearc segments of the laminated film configured to conform only to part orall of the peripheral portion of the article, with each segment havingends that are configured to intersect with the ends of the other segmentto ensure conformance of the IML to the peripheral portion of thearticle; providing a mold used in a molding process during which themolded article is fabricated, with the mold having a mold cavity formedby first and second molding surfaces with the first surfacecorresponding to the front side of the article and the second surfacecorresponding to the back side of the article, into which cavity resinis deposited to form the article and from which the molded article isextracted, with the mold configured to provide the article with acentral portion bounded by a peripheral portion having a perimeter andincluding an outer boundary located near the perimeter and an innerboundary located near the central portion, with the outer and innerboundaries of the peripheral portion being oriented at an angle or slopeand/or being curved with respect to the central portion of the moldedarticle; transferring the IML to the mold so that the printed surface ofeach arc segment is placed adjacent one of the molding surfaces of themold cavity in a position corresponding to and within the peripheralportion of the article with the ends of each arc segment configured forplacement to form intersecting ends of adjacent arc segments to ensureconformance of the IML to the angled, sloped and/or curved peripheralportion of the article; closing the mold by bringing the other of themolding surfaces into position to form the mold cavity; delivering theresin to the mold cavity having the IML therein wherein the ends of thearc segments are fixed in place to intersect during molding of thearticle; and recovering the molded article from the mold with the IMLpresent only upon the peripheral portion of the molded article.
 2. Themethod of claim 1, wherein the peripheral portion transitions from theouter boundary to the inner boundary by a shallow-angled or slopedsurface such that the peripheral portion is configured as a shallow,open conical surface, wherein the IML is provided only within the innerand outer boundaries of the peripheral portion.
 3. The method of claim1, wherein the IML is electrostatically charged prior to disposition inthe mold and the printed surface of the IML includes one or moreaesthetic designs.
 4. The method of claim 1, wherein the IML is placedon the mold surface that forms the front side of the molded article,with the backing layer of the IML contacting the peripheral portion ofthe front side of the molded article and the protective layer formingpart of a front surface of the molded article, with the protective filmlayer being sufficiently transparent so that the aesthetic design isvisible therethrough.
 5. The method of claim 1, wherein the IML isplaced on the mold surface that forms the back side of the moldedarticle, with the backing layer of the IML contacting the peripheralportion of the back side of the molded article and the protective filmlayer forming part of a back surface of the back side of the moldedarticle, with the molded article and backing layer being sufficientlytransparent so that the aesthetic design is visible therethrough.
 6. Themethod of claim 1, the backing layer comprises a clear layer ofpolypropylene or polystyrene, the protective film layer comprisespolypropylene or polyester and the method further comprises subjectingthe resin to a heating and cooling cycle for controlling resin flow andretaining the molded article shape.
 7. The method of claim 1, whereinthe ends of the IML segments overlap by a minimum intersection of 0.5mm.
 8. The method of claim 1, wherein the molded article and IML have around or oval perimeter.
 9. The method of claim 8, wherein the moldedarticle and IML have a round perimeter and two arc segments areprovided.
 10. The method of claim 1, further comprising providing themold with an integral shelf configured to retain the IML on the moldsurface during the molding process and further configured to directresin flow beyond an IML edge while avoiding entry of resin between thelabel and the mold surface, wherein the shelf has a height about threetimes a thickness of the IML.
 11. The method of claim 1, which furthercomprises providing a magazine to hold multiple IMLs in place fortransfer to the mold surface and wherein the molded article comprises aplastic plate having a plate profile selected from a plurality of round,oval or polygonal plate profiles or combinations thereof.
 12. The methodof claim 1, wherein the IML includes printing on both sides of thebacking layer and the molded article is made of clear resin so that theprinting is visible from both the front and back sides of the moldedarticle.
 13. A method of making a molded article having front and backsides and a central portion bounded by a peripheral portion having aperimeter and including an outer boundary located near the perimeter andan inner boundary located near the central portion, with the peripheralportion on the front side of the article transitioning from the outerboundary to the inner boundary by a transition surface comprising acombination of a shallow-angled or sloped surface and a curved surfacesuch that the shallow-angled or sloped surface of the peripheral portionis configured as an open conical surface, and with the article includingan in mold label (IML) on the transition surface of the peripheralportion of the article, which method comprises: providing an in-moldlabel comprising: a laminated film that includes a backing layer, aprinted surface supported by the backing layer, with the printed surfaceincorporating one or more designs thereon, and a protective film layerupon the printed surface, with the laminated film configured in at leasttwo separate arc segments that conform to the shallow-angled or slopedsurface of the peripheral portion of the article, with each arc segmentconfigured for placement to form intersecting ends the ends of the othersegment to ensure conformance of the IML to the peripheral portion ofthe article, with the IML including a central segment for application tothe central portion of the molded article and with each arc segment ofthe IML including a connection neck extending between the inner boundaryof the arc segments and the central segment over the curved surface,wherein the arc segments of the IML are provided within the inner andouter boundaries of the peripheral portion; providing a mold used in amolding process during which the molded article is fabricated, with themold having a mold cavity formed by first and second molding surfaceswith the first surface corresponding to the front side of the articleand the second surface corresponding to the back side of the article,with the mold configured to provide the molded article with a centralportion bounded by a peripheral portion having a perimeter and includingan outer boundary located near the perimeter and an inner boundarylocated near the central portion, with the peripheral portiontransitioning from the outer boundary to the inner boundary by atransition surface comprising a combination of a shallow-angled orsloped surface and a curved surface and into which mold cavity resin isdeposited to form the article and from which the molded article isextracted; transferring the IML to the mold so that the printed surfaceof each arc segment is placed adjacent one of the molding surfaces ofthe mold cavity in a position corresponding to and within the peripheralportion of the article with the ends of each arc segment configured forplacement to form intersecting ends of the other arc segment to ensureconformance of the IML to the angled, sloped and/or curved peripheralportion of the article, and with the connection necks provided upon thecurved surface of the molded article; closing the mold by bringing theother of the molding surfaces into position to form the mold cavity;delivering the resin to the mold cavity having the IML therein whereinthe ends of the arc segments are fixed in place to intersect duringmolding of the article; and recovering the molded article from the moldwith the IML present both on the peripheral and central portions and onportions of the curved surface of the molded article.
 14. The method ofclaim 13, wherein two arc segments are provided and the ends of the IMLsegments overlap by a minimum intersection of 0.5 mm.
 15. The method ofclaim 13, the backing layer comprises a clear layer of polypropylene orpolystyrene, the protective film layer comprises polypropylene orpolyester and the method further comprises subjecting the resin to aheating and cooling cycle for controlling resin flow and retaining themolded article shape.
 16. A method of making a molded article havingfront and back sides and a central portion bounded by a peripheralportion having a perimeter and including an outer boundary located nearthe perimeter and an inner boundary located near the central portion,wherein the peripheral portion on the front side of the article on thefront side of the article includes a transition from the inner boundaryto the central portion of the article which is a shallow-angled orsloped surface, a curved surface or combinations thereof, and with thearticle including an in mold label (IML) at least on the angled, slopedand/or curved peripheral portion of the article, which method comprises:providing a first in-mold label comprising at least two separate arcsegments of a laminated film that includes a backing layer, a printedsurface supported by the backing layer, with the printed surfaceincorporating one or more designs thereon, and a protective film layerupon the printed surface, with the arc segments of the laminated filmconfigured to conform only to part or all of the peripheral portion ofthe article, with each segment having ends that are configured tointersect with the ends of the other segment to ensure conformance ofthe IML to the peripheral portion of the article; providing a second IMLof a laminated film that includes a backing layer, a printed surfacesupported by the backing layer, with the printed surface incorporatingone or more designs thereon, and a protective film layer upon theprinted surface, wherein the second IML includes a central segment forapplication to the central portion of the molded article; providing amold used in a molding process during which the molded article isfabricated, with the mold having a mold cavity formed by first andsecond molding surfaces with the first surface corresponding to thefront side of the article and the second surface corresponding to theback side of the article, into which cavity resin is deposited to formthe article and from which the molded article is extracted, with themold configured to provide the article with a central portion bounded bya peripheral portion having a perimeter and including an outer boundarylocated near the perimeter and an inner boundary located near thecentral portion, with the outer and inner boundaries of the peripheralportion being oriented at an angle or slope or being curved with respectto the central portion of the molded article; transferring the first andsecond IMLs to the mold so that the printed surface of each arc segmentis placed adjacent one of the molding surfaces of the mold cavity in aposition corresponding to and within the peripheral portion of thearticle with the ends of each arc segment configured for placement toform intersecting ends of adjacent arc segments to ensure conformance ofthe first IML to the angled, sloped and/or curved peripheral portion ofthe article; closing the mold by bringing the other of the moldingsurfaces into position to form the mold cavity; delivering the resin tothe mold cavity having the IMLs therein wherein the ends of the arcsegments of the first IML are fixed in place to intersect during moldingof the article; and recovering the molded article from the mold with theIMLs respectively present upon the peripheral and central portions ofthe molded article such that the molded article includes a ring of theat least two separate arc segments within the inner and outer boundarieson the peripheral portion of the article and the central segment on thecentral portion of the article, wherein the central segment is spacedfrom and not in contact with the ring of arc segments.
 17. The method ofclaim 1 wherein each arc segment has exposed straight ends that areconfigured to intersect with the straight ends of the other segment. 18.The method of claim 16, wherein the IML is placed on the mold surfacethat forms the front side of the molded article, with the backing layerof the IML contacting the peripheral portion of the front side of themolded article and the protective layer forming part of a front surfaceof the molded article, with the protective film layer being sufficientlytransparent so that the aesthetic design is visible therethrough. 19.The method of claim 16, wherein the IML is placed on the mold surfacethat forms the back side of the molded article, with the backing layerof the IML contacting the peripheral portion of the back side of themolded article and the protective film layer forming part of a backsurface of the back side of the molded article, with the molded articleand backing layer being sufficiently transparent so that the aestheticdesign is visible therethrough.
 20. The method of claim 16, the backinglayer comprises a clear layer of polypropylene or polystyrene, theprotective film layer comprises polypropylene or polyester and themethod further comprises subjecting the resin to a heating and coolingcycle for controlling resin flow and retaining the molded article shape.